Functionalised graphene nanoparticle barrier films for sustainable food packaging
Plasma-functionalised graphene nanoplatelet barrier films reduce gas permeability, moisture transfer, and microbial contamination while improving mechanical strength and flexibility. Films can enable lightweighting by reducing thickness while maintaining oxygen and moisture barrier performance, and can provide antibacterial and UV-blocking functions with optical transparency. Demonstrated in commercial zipper bags with higher tensile strength, supporting shelf-life extension and reduced material usage in food packaging formats.
Overview
Functionalised graphene nanoparticle barrier films provide an advanced packaging approach to extend shelf life and preserve packaged food quality. By incorporating plasma-functionalised graphene nanoplatelets (GNPs) into packaging materials, the films reduce gas permeability, moisture transfer, and microbial contamination. The resulting barrier films are designed to deliver enhanced mechanical strength and flexibility, broad application versatility, and improved environmental sustainability compared to conventional plastic packaging.
Technical specifications
Key features:
- Plasma functionalisation process: An environmentally friendly method that engineers graphene and other nanomaterials at the atomic level to enhance strength, durability, and barrier performance
- Enhanced mechanical strength: Films incorporating GNPs demonstrate a 31% increase in tensile strength compared to non-graphene LLDPE (linear low-density polyethylene)
- Lightweighting capability: Increased mechanical strength enables film thickness reduction from 90µm to 60µm while maintaining oxygen and moisture barrier protection
- Antibacterial function: Graphene addition suppresses microbial growth, reducing the risk of foodborne illness and extending product shelf life
- UV protection: Integrated UV-blocking properties help keep food fresher for longer
- Optical transparency: Films remain transparent enough to view packaged food contents
- Application versatility: Compatible with existing food storage formats including zipper bags and biodegradable plastic bags
Technology readiness level
The technology has been validated through initial commercial supply to a plastics developer, where functionalised GNPs were used to manufacture food storage zipper bags and biodegradable plastic bags. The bags demonstrated measurable improvements in tensile strength, barrier performance, antibacterial function, and UV protection in real-world food packaging applications.
A structured validation programme is planned, including defined objectives, experimental design across varied food types (different pH and fat content), application of GNP films to packaging materials, and comprehensive testing of gas permeability, moisture transfer, and microbial growth. Results will be analysed using statistical methods and documented in a final research report and demonstration.
The technology is at an advanced stage suitable for pilot trials, co-development partnerships, and licensing engagements with food manufacturers and packaging companies.
About Haydale
Haydale PLC is an advanced materials and clean technology group headquartered in Wales that specializes in the development and deployment of energy and water-efficient technologies. At the core of its operations is the proprietary HDPlas® platform, an environmentally friendly technology used for the plasma functionalization of graphene and other nanomaterials. This process engineers materials at the atomic level to enhance properties such as strength, durability, thermal conductivity, and electrical performance, enabling the creation of advanced graphene-enabled products designed to deliver measurable energy, water, and carbon savings.
The group operates through an integrated commercial model that translates this materials science into deployable solutions, including its JustHeat electric underfloor heating system, which utilizes graphene-based conductive inks for efficient, low-carbon temperature control. Additionally, Haydale leverages SaveMoneyCutCarbon, an embedded B2B platform that provides a national sales, programme management, and installer network. By utilizing an Impact Partner Programme to originate demand through agreements with UK banks and utilities, the company facilitates the scalable deployment of its decarbonization solutions across the built environment, addressing the growing market demand for sustainable and future-ready infrastructure.
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